A New Sled for Winter!

BABY BEAR: I made my first cross-cut sled following plans from Woodsmith Shop. In general, I liked the shape as the cut-out area made it easier to handle. However, for me, the design was too complicated and introduced some problems. The sliding base (to allow wide kerfs or even dado blades) produced some inaccuracy as did the Kreg Swing Stop which, because of it’s design, allows for some side-to-side movement. Finally, the sled’s design calls for an additional bolt-on fence extension for cuts over 20” long. This sled was too small!

PAPA BEAR: I then researched the Web for new ideas on building a good sled that was considerably bigger than my first. I found a design that looked really “beefy” from Fine Woodworking. It was 3/4” MDF with very solid fences and had the addition of a safety box. This sled was big, it was accurate, it was heavy. This design also lacked a built-in tape measure and stop block which was a convenience I missed. After using this sled for about a year I just got tired of lifting this beast onto my saw table. This sled was too heavy!

MAMA BEAR: Now knowing what didn’t work for me, I designed this sled with careful consideration for accuracy, ease of handling, sled weight and the length of material I generally use. I also wanted the convenience of a built-in tape measure with a stop block (that didn’t wiggle) and adjustable miter slot sliders (Kreg). I incorporated ideas from my previous sleds and some from other designs I found on the Web. I have used this one for a number of weeks now. This sled is just right!

10/23/2015 ADDENDUM: I acted on the suggestion that the safety box was larger than it needed to be and so I re-engineered it! I think the new size is more appropriate, makes the sled look better and saves a little weight. The photos show the re-engineered sled.

-- Jerry, Johnson Creek, WI "If it was meant to be different it would be."

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18 comments so far

As usual you have outdone the average bear (pun intended). Instead of Mama Bear, I would call it Goldilocks – just right. Pays to do your research – you nailed the criteria and your execution was flawless. I am going to copy it.

-- Don, Silver City New Mexico, parsimony, utility and elegance - blueprint for any project.

That is one fine looking sled, sir. I have a couple of questions just by way of revealing my ignorance:1. there are what appear to be two vertical groves on the forward upright: Purpose?2. what is the box structure on the back side for?

Thanks for the questions, appreciate your interest!-The sled measures 15 3/4” wide (+3” for the fences) and 38” long.-To insure that it cuts a perfect 90º angle I watched a You Tube video (also available on Lumberjacks) 5 Cuts To A “Perfect” Cross Cut Sled, William Ng Woodworks.-The Kreg miter sliders are adjustable from the top of the sled. There are three adjusters for each slide. The vertical cuts on the front fence allow me to access the front two adjusters.-Yes, the box on the back is for safety (although I do have a SawStop). And yes, I could have made it 1 1/2” shorter than it is. With the blade fully extended, I only need about 4 1/2” of depth to the box. As far as the width; I didn’t want some dinky thing that would get knocked off. Thanks for the comment WoodNSawdust!, I will make that adjustment to the box depth!

-- Jerry, Johnson Creek, WI "If it was meant to be different it would be."

Nice and practical looking sled that should do for many more then one winter .As to the blade safety box yes it is a little big but so what I addressed the issue with stop blocks that limit the sled travel which I installed in the mitre grooves on the out feed table .http://lumberjocks.com/projects/165970